2007 YAMAHA XMAX 250 wheel

DECLARATION of CONFORMITY
WeCompany: MORIC CO., LTD.
Address: 1450-6 Mori Mori-Machi Shuchi-gun Shizuoka 437-0292 Japan
Hereby declare that the product:
Kind of equipment: IMMOBILIZER
Type-designation: 5SL-00
is in compliance with following norm(s) or documents:
R&TTE Directive(1999/5/EC)
EN300 330-2 v1.1.1(2001-6), EN60950-1(2001)
Two or Three-Wheel Motor Vehicles Directive(97/24/EC: Chapter 8, EMC)
Place of issue: Shizuoka, Japan
Date of issue: 1 Aug. 2002
Revolution record
No. Contents Date
To change contact person and integrate type-designation. 9 Jun. 2005
General manager of quality assurance div.
representative name and signature
MORIC CO., LTD.1450-6 Mori-machi Shuchi-gun Shizuoka 437-0292 JAPAN Telephone +81-538-85-0757 Facsimile +81-538-85-0456URL:http://www.moric-jp.com
1Version up the norm of EN60950 to EN60950-1 27 Feb. 20062
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INTRODUCTION
IMPORTANT MANUAL INFORMATION
TABLE OF CONTENTS
SAFETY INFORMATION.....................1-1
Further safe-riding points .................1-4
DESCRIPTION.....................................2-1
Left view ...........................................2-1
Right view .........................................2-2
Controls and instruments .................2-3
INSTRUMENT AND CONTROL
FUNCTIONS........................................3-1
Immobilizer system ...........................3-1
Main switch/steering lock .................3-2
Indicator and warning lights .............3-3
Speedometer ....................................3-4
Fuel gauge ........................................3-4
Coolant temperature gauge..............3-5
Multi-function display .......................3-5
Anti-theft alarm (optional) .................3-8
Handlebar switches ..........................3-9
Front brake lever.............................3-10
Rear brake lever..............................3-10
Fuel tank cap ..................................3-11
Fuel .................................................3-12
Catalytic converter..........................3-13
Seat.................................................3-13
Storage compartments ...................3-14Front storage compartment............3-15
Rear storage compartment.............3-16
Adjusting the shock absorber
assemblies...................................3-17
Sidestand ........................................3-17
Ignition circuit cut-off system .........3-18
PRE-OPERATION CHECKS...............4-1
Pre-operation check list....................4-2
OPERATION AND IMPORTANT RIDING
POINTS................................................5-1
Starting a cold engine ......................5-1
Starting off ........................................5-2
Acceleration and deceleration ..........5-2
Braking..............................................5-3
Tips for reducing fuel consumption..5-3
Engine break-in.................................5-4
Parking ..............................................5-4
PERIODIC MAINTENANCE AND
MINOR REPAIR...................................6-1
Owner’s tool kit .................................6-1
Periodic maintenance and
lubrication chart ............................6-3
Removing and installing the
cowlings and panel .......................6-6
Checking the spark plug ..................6-7
Engine oil ..........................................6-8
Final transmission oil ......................6-10
Coolant ...........................................6-11Air filter and V-belt case air filter
elements ......................................6-12
Adjusting the throttle cable free
play ..............................................6-14
Valve clearance ...............................6-14
Tires ................................................6-15
Cast wheels ....................................6-17
Front and rear brake lever free
play ..............................................6-17
Checking the front and rear brake
pads.............................................6-18
Checking the brake fluid level ........6-18
Changing the brake fluid ................6-19
Checking and lubricating the
cables ..........................................6-20
Checking and lubricating the
throttle grip and cable .................6-20
Lubricating the front and rear
brake levers .................................6-20
Checking and lubricating the
centerstand and sidestand .........6-21
Checking the front fork ...................6-21
Checking the steering.....................6-22
Checking the wheel bearings .........6-23
Battery ............................................6-23
Replacing the fuses ........................6-24
Replacing a headlight bulb .............6-25
Replacing a front turn signal light
bulb .............................................6-27
Replacing the tail/brake light bulb or a
rear turn signal light bulb ............6-27
TABLE OF CONTENTS
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The posture of the operator and
passenger is important for proper
control.
• The operator should keep both
hands on the handlebar and
both feet on the footboard
during operation to maintain
control of the scooter.
• The passenger should always
hold onto the operator, the seat
strap or grab bar, if equipped,
with both hands and keep both
feet on the passenger foo-
trests.
• Never carry a passenger
unless he or she can firmly pla-
ce both feet on the passenger
footrests.
Never ride under the influence of
alcohol or other drugs.
This scooter is designed for on-
road use only. It is not suitable for
off-road use.
Protective apparel
The majority of fatalities from scooter
accidents are the result of head inju-
ries. The use of a safety helmet is the
single most critical factor in the pre-
vention or reduction of head injuries.
Always wear an approved hel-
met.
Wear a face shield or goggles.
Wind in your unprotected eyes
could contribute to an impair-
ment of vision which could delay
seeing a hazard.
The use of a jacket, substantial
shoes, trousers, gloves, etc., is
effective in preventing or redu-
cing abrasions or lacerations.
Never wear loose-fitting clothes,
otherwise they could catch on
the control levers or wheels and
cause injury or an accident.
Never touch the engine or
exhaust system during or after
operation. They become very hot
and can cause burns. Always
wear protective clothing that
covers your legs, ankles, and
feet.
Passengers should also observe
the above precautions.
Modifications
Modifications made to this scooter
not approved by Yamaha, or the
removal of original equipment, may
render the scooter unsafe for use andmay cause severe personal injury.
Modifications may also make your
scooter illegal to use.
Loading and accessories
Adding accessories or cargo to your
scooter can adversely affect stability
and handling if the weight distribution
of the scooter is changed. To avoid
the possibility of an accident, use
extreme caution when adding cargo
or accessories to your scooter. Use
extra care when riding a scooter that
has added cargo or accessories. Here
are some general guidelines to follow
if loading cargo or adding accessories
to your scooter:
Loading
The total weight of the operator, pas-
senger, accessories and cargo must
not exceed the maximum load limit.
When loading within this weight limit,
keep the following in mind:
Cargo and accessory weight
should be kept as low and close
Maximum load:
180 kg (396.9 lb)
1
SAFETY INFORMATION
1-2
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EAU15605
Pre-operation check list
PRE-OPERATION CHECKS
4-2
4
ITEM CHECKS PAGE
• Check fuel level in fuel tank.
Fuel• Refuel if necessary. 3-4, 3-12
• Check fuel line for leakage.
• Check oil level in engine.
Engine oil• If necessary, add recommended oil to specified level. 6-8
• Check vehicle for oil leakage.
Final transmission oil• Check vehicle for oil leakage. 6-10
• Check coolant level in reservoir.
Coolant• If necessary, add recommended coolant to specified level. 6-11
• Check cooling system for leakage.
• Check operation.
• If soft or spongy, have Yamaha dealer bleed hydraulic system.
• Check brake pads for wear.
Front brake• Replace if necessary. 3-10, 6-17 ~ 6-19
• Check fluid level in reservoir.
• If necessary, add recommended brake fluid to specified level.
• Check hydraulic system for leakage.
• Check operation.
• If soft or spongy, have Yamaha dealer bleed hydraulic system.
• Check brake pads for wear.
Rear brake• Replace if necessary. 3-10, 6-17 ~ 6-19
• Check fluid level in reservoir.
• If necessary, add recommended brake fluid to specified level.
• Check hydraulic system for leakage.
• Make sure that operation is smooth.
Throttle grip• Check cable free play.
5-2, 6-14, 6-20
• If necessary, have Yamaha dealer adjust cable free play
and lubricate cable and grip housing.
• Check for damage.
Wheels and tires• Check tire condition and tread depth.
6-15 ~ 6-17, 6-23
• Check air pressure.
• Correct if necessary.
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ODOMETER READING (x 1000 Km) ANNUAL
NO. ITEM CHECK OR MAINTENANCE JOB CHECK
110203040
8* Brake hose • Check for cracks or damage.
√√√√ √• Replace. Every 4 years
9*Wheels • Check runout and for damage. √√√√
• Check tread depth and for damage.
10 * Tires • Replace if necessary.
√√√√ √
• Check air pressure.
• Correct if necessary.
11 * Wheel bearings • Check bearing for looseness or damage. √√√√
12 *Steering bearings • Check bearing play and steering for roughness.
√√ √ √√• Lubricate with lithium-soap-based grease. Every 20000 km
13 * Chassis fasteners • Make sure that all nuts, bolts and screws are
properly tightened. √√√√ √
14 Sidestand, centerstand • Check operation.
• Lubricate. √√√√ √
15 *
Sidestand switch • Check operation. √√ √ √√ √
16 *Front fork • Check operation and for oil leakage. √√√√
17 * Shock absorber
assemblies • Check operation and shock absorbers for oil leakage.
√√√√
18 *Fuel injection • Check engine idle speed. √√ √ √√ √
• Change. (See pages 6-8.) √When the oil change indicator flashes
19
Engine oil (every 3000 km)• Check oil level and vehicle for oil leakage. Every 3000 km
√
20 *Engine oil strainer • Clean. √
21 *Cooling system • Check coolant level and vehicle for coolant leakage.
√√√√ √
• Change. Every 3 years
PERIODIC MAINTENANCE AND MINOR REPAIR
6-4
6
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6. Add the specified amount of the
recommended final transmission
oil, and then install and tighten
the oil filler cap.
EWA11310
s s
WARNING
Make sure that no foreign
material enters the final trans-
mission case.
Make sure that no oil gets on
the tire or wheel.
7. Check the final transmission case
for oil leakage. If oil is leaking,
check for the cause.
EAU20070
Coolant
The coolant level should be checked
before each ride. In addition, the coo-
lant must be changed at the intervals
specified in the periodic maintenance
and lubrication chart.
EAUS1272
To check the coolant level
1. Place the vehicle on a level surfa-
ce and hold it in an upright posi-
tion.
NOTE:
The coolant level must be chec-
ked on a cold engine since the
level varies with engine tempera-
ture.
Make sure that the vehicle is
positioned straight up when
checking the coolant level. A
slight tilt to the side can result in
a false reading.
2. Check the coolant level through
the check window.
1. Maximum level mark
2. Minimum level mark
3. Coolant level window
NOTE:
The coolant should be between the
minimum and maximum level marks.
3. If the coolant is at or below the
minimum level mark, remove the
right floorboard mat by pulling it
up.
4. Open the reservoir cap, and then
add coolant to the maximum
level mark.
Recommended final transmission
oil:
See page 8-1.
Oil quantity:
0.25 L (0.26 US qt) (0.22 Imp.qt)
Tightening torque:
Final transmission oil drain bolt:
22 Nm (2.2 m•kgf, 15.9 ft•lbf)
PERIODIC MAINTENANCE AND MINOR REPAIR
6-11
6
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Check the tire condition and air
pressure before each ride.
1. Tire tread depth
Tire inspection
The tires must be checked before
each ride. If the center tread depth
reaches the specified limit, if the tire
has a nail or glass fragments in it, or if
the sidewall is cracked, have a Yama-
ha dealer replace the tire immediately.
NOTE:
The tire tread depth limits may differ
from country to country. Always
comply with the local regulations.
Tire information
This motorcycle is equipped with
tubeless tires.
EWA10470
s s
WARNING
Have a Yamaha dealer replace
excessively worn tires. Besides
being illegal, operating the
vehicle with excessively worn
tires decreases riding stability
and can lead to loss of control.
The replacement of all wheel
and brake related parts, inclu-
ding the tires, should be left to
a Yamaha dealer, who has the
necessary professional know-
ledge and experience.
Front tire:
Size:
120/70-15 M/C 56S(Michelin)
120/70-15 M/C 56P(Pirelli)
Manufacturer/model:
Michelin/GoldStandard
Pirelli/GTS23
Rear tire:
Size:
140/70-14 M/C 68S(Michelin)
140/70-14 M/C 68P(Pirelli)
Manufacturer/model:
Michelin/GoldStandard
Pirelli/GTS24
Minimum tire tread depth (front
and rear):
1.6 mm (0.06 in)
1
ZAUM0054
PERIODIC MAINTENANCE AND MINOR REPAIR
6-16
6
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EAU21960
Cast wheels
To maximize the performance, durabi-
lity, and safe operation of your
motorcycle, note the following points
regarding the specified wheels.
The wheel rims should be chec-
ked for cracks, bends or warpage
before each ride. If any damage
is found, have a Yamaha dealer
replace the wheel. Do not
attempt even the smallest repair
to the wheel. A deformed or crac-
ked wheel must be replaced.
The wheel should be balanced
whenever either the tire or wheel
has been changed or replaced.
An unbalanced wheel can result
in poor performance, adverse
handling characteristics, and a
shortened tire life.
Ride at moderate speeds after
changing a tire since the tire sur-
face must first be “broken in” for
it to develop its optimal characte-
ristics.
EAU33453
Front and rear brake lever
free play
Front
RearThere should be no free play at the
brake lever ends. If there is free play,
have a Yamaha dealer inspect the
brake system.EWA14211
s s
WARNING
A soft or spongy feeling in the bra-
ke lever can indicate the presence
of air in the hydraulic system. If the-
re is air in the hydraulic system,
have a Yamaha dealer bleed the
system before operating the vehi-
cle. Air in the hydraulic system will
diminish the braking performance,
which may result in loss of control
and an accident.
PERIODIC MAINTENANCE AND MINOR REPAIR
6-17
6
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